Classifications

• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
  • D04H1/645—Impregnation followed by a solidification process
  • D04H1/65—Impregnation followed by a solidification process using mixed or composite fibres
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
  • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
  • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
  • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
  • C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/425—Cellulose series
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
  • D04H1/4274—Rags; Fabric scraps
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
  • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
  • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
  • D04H1/64—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
• • D—TEXTILES; PAPER
  • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
  • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
  • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
  • D06N3/0002—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate
  • D06N3/0011—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof characterised by the substrate using non-woven fabrics
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21B—FIBROUS RAW MATERIALS OR THEIR MECHANICAL TREATMENT
  • D21B1/00—Fibrous raw materials or their mechanical treatment
  • D21B1/04—Fibrous raw materials or their mechanical treatment by dividing raw materials into small particles, e.g. fibres
  • D21B1/06—Fibrous raw materials or their mechanical treatment by dividing raw materials into small particles, e.g. fibres by dry methods
  • D21B1/08—Fibrous raw materials or their mechanical treatment by dividing raw materials into small particles, e.g. fibres by dry methods the raw material being waste paper; the raw material being rags
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21C—PRODUCTION OF CELLULOSE BY REMOVING NON-CELLULOSE SUBSTANCES FROM CELLULOSE-CONTAINING MATERIALS; REGENERATION OF PULPING LIQUORS; APPARATUS THEREFOR
  • D21C5/00—Other processes for obtaining cellulose, e.g. cooking cotton linters ; Processes characterised by the choice of cellulose-containing starting materials
  • D21C5/02—Working-up waste paper
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
  • D21H11/14—Secondary fibres
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/26—Scrap or recycled material
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2300/00—Characterised by the use of unspecified polymers
  • C08J2300/22—Thermoplastic resins
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
  • C08J2300/00—Characterised by the use of unspecified polymers
  • C08J2300/30—Polymeric waste or recycled polymer
• • D—TEXTILES; PAPER
  • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
  • D10B2401/00—Physical properties
  • D10B2401/04—Heat-responsive characteristics
  • D10B2401/041—Heat-responsive characteristics thermoplastic; thermosetting

Definitions

• the invention relates to a process for producing non-woven fabric-like composite materials, novel non-woven fabric-like composite materials and their use.
• the fabric-like composite materials are derived from shredded polymer-glued or polymer-coated paper products and coffee grounds as raw material.
• a first step is the increased use of renewable raw materials in technical areas such as automotive, consumer goods etc., which temporarily store CO 2 at least for a few years and are neutral in the CO 2 balance in the short term during this phase of use.
• One raw material relevant to the invention are paper products with polymer-coating or which otherwise contain polymers, e.g. as a glue material.
• Such polymer-containing (polymer-coated) paper products are produced in large quantities worldwide and are widely used as printed advertisement or catalogue materials, disposable paper products, including polymer-coated paper take-away cups, dishes, bowls, bags, and beverage cartons, or printed packages for all kind of products.
• waste-paper After use such polymer-containing paper products are usually burned or recycled as “waste-paper” or “recovered paper.”
• recycling means a process of converting waste materials into new materials and objects or their raw materials are turned into secondary raw materials.
• the recovery of energy from waste materials is often included in this concept.
• the recyclability of a material depends on its ability to reacquire the properties it had in its virgin or original state.
• a specific aspect of recycling methods is the so-called upcycling, which describes a creative reuse of the waste materials, and which is a process of transforming by-products, waste materials, useless, or unwanted products into new materials or products perceived to be of greater quality or environmental value.
• the recovery of waste-paper from paper products is of high economic importance in the paper industry to save resources.
• waste-paper or “recovered paper” is based on DIN 6730 and is therein defined as paper or cardboard that is returned from production or processing in used or unused form to be fed back into a manufacturing process as semi-finished material.
• the recovered paper use rate i.e. the share of recovered paper in total domestic paper production, was 65% in 2003.
• recovered paper is used as a secondary raw material in paper and cardboard production.
• waste-paper cannot be recycled as often as desired. With each recycling cycle, the fibers are shortened due to mechanical stress and lose the ability to reconnect into a sheet structure after about 4 to 6 cycles, which in turn has a negative impact on paper strength.
• the contamination of the recycled paper increases with an increase in the number of recycling cycles, as inorganic and especially organic impurities, such as polymers, cannot be completely separated and consequently accumulate.
• PE polyethylene
• polyacrylates or polystyrene acrylates or other vinyl polymers or polyesters have been known for a long time, especially in the fields of foodstuffs (e.g. for beverages), cosmetics and cleaning agents, whereby the PE film or the other polymers used can be applied as a very thin barrier coating on the inside, outside and/or also between the different paper layers.
• a paper product is coated with PE film or the other polymers to be used on at least one of the two surfaces.
• thermoplastic composite materials comprising at least one organic fiber material and at least one thermoplastic binder, such as bonded leather materials (LeFa).
• the process makes use of animal-based raw materials and is limited to the use of thermoplastic binders.
• the inventors of the present invention surprisingly found a further new method of upcycling coffee grounds and polymer-coated paper waste products at the same time to obtain not only non-elastic/non-flexible panels or boards but completely new fabric-like composite materials.
• Such new fabric-like composite materials are comparable to known reconstituted fiber-based fabric like materials like bonded leather or similar products based on cellulose fibers.
• the new fabric-like products obtainable with the new process of the present invention can therefore also be considered as bonded leather substitute and therewith provide a non-animal-based substitute, which is of particular interest in view of the increasing demand for animal-friendly and vegan products.
• an object of the present invention is to provide a (further) new upcycling process for providing not only recycled (recovered) paper and coffee grounds but new products of higher value based on the polymer-coated paper waste and coffee grounds.
• a further object of the present invention is to provide a process for producing a non-woven, fabric-like material, which is based on shredded (particulated) polymer-coated paper products and/or coffee grounds and can be produced at low cost.
• a further object relates to providing new fabric-like composite materials as substitutes for the known reconstituted cellulose- and leather-based fabrics (such as bonded leather).
• a further object relates to providing new (reconstituted) non-woven fabrics and textiles or non-woven fabric-/textile-like surface covers for indoor applications, furniture, industrial and home textiles and decoration, clothing, shoes, and bags manufacturing.
• a further object of the invention was to provide a cost and energy saving process for recycling/upcycling paper waste products and coffee grounds.
• the present invention relates to the fabric-like composite materials prepared from particle/polymer composites based on a mixture of shredded polymer-glued or polymer-coated paper products and coffee grounds and which can be obtained with the new method according to the invention.
• a further aspect of the invention relates to the use of such fabric-like composite materials for the manufacturing of non-woven fabric- or textile-like materials, such as for elements in buildings, including surface covers for indoor applications, such as wall covers, table laminates, floors, tiles, counters, or for furniture, industrial and home textiles and decorative textiles, for clothing and in bag and shoe manufacturing.
• the relation between the three components of the mixture of the substrate S with the polymer P can vary in the range of 30-85:0-60:10-45 weight % dry matter.
• residual moisture content is understood to be the percentage difference in weight, relative to the substrate S/polymer P mixture used, which results when 1 g of substrate S/polymer P mixture is dried in a drying oven at 120° C. for one hour.
• the paper with dispersion-based internal coating (for beverages) is comminuted using an Alpine cutting mill and water (5% solids) and then ground in a grinding roller mill with further addition of water so that a solids content of 2% is achieved.
• a grinding degree of 35-45 SR according to Schopper Riegler is aimed for.
• the coffee grounds are added, diluted with the appropriate amount of water to a solids content of 2%.
• the dispersion is slowly added to the fiber/coffee grounds slurry while stirring. When a good mixing is achieved, the Polymin SK is added. After a few minutes the liquor should be clear.
• the end point of precipitation can be seen when a sample of the fiber pulp poured onto a filter or sieve gives a clear filtrate.
• the cellulose fiber/coffee grounds/binder liquor is dewatered on a sheet former with a screen size of 20 ⁇ 20 cm. The dewatering is accelerated by applying a vacuum.
• the resulting fiber cake is further dewatered and compacted in a stacking press between rubber, filter paper, screen and a damp cloth. (Structure in the press: Rubber mat, filter paper, sieve, damp cloth, fiber CS cake, damp cloth, sieve, filter paper, rubber mat).
• the fiber coffee cake obtained in this way is then dried at RT or at temperatures of up to 100° C.
• the dried board obtained in this way can then be further compacted in a press after 24 hours of conditioning.
• the sheet produced in this way has a thickness of 1.3 mm and a density of 0.85 g/cm 3 .
• the tensile strength, the elongation and the tear strength are determined on the plate.
• the paper with dispersion-based internal coating (for beverages) is comminuted using an Alpine cutting mill and water (5% solids) and then ground in a grinding roller mill with further addition of water so that a solids content of 2% is achieved.
• a grinding degree of 35-45 SR according to Schopper Riegler is aimed for.
• the coffee grounds are added, diluted with the appropriate amount of water to a solids content of 2%.
• the dispersion is slowly added to the fiber/coffee grounds slurry while stirring.
• the Polymin SK is added. After a few minutes the liquor should be clear. The end point of precipitation can be seen when a sample of the fiber pulp poured onto a filter or sieve gives a clear filtrate.
• the cellulose fiber/coffee grounds/binder liquor is dewatered on a sheet former with a screen size of 20 ⁇ 20 cm.
• the dewatering is accelerated by applying a vacuum.
• the resulting fiber cake is further dewatered and compacted in a stacking press between rubber, filter paper, screen and a damp cloth.
• Structure in the press Rubber mat, filter paper, sieve, damp cloth, fiber CS cake, damp cloth, sieve, filter paper, rubber mat.
• the fiber coffee cake obtained in this way is then dried at RT or at temperatures of up to 100° C.
• the dried board obtained in this way can then be further compacted in a press after 24 hours of conditioning.
• the sheet produced in this way has a thickness of 1.40 mm and a density of 0.78 g/cm 3 .
• the tearing force, the elongation and the tear propagation force are determined on the panel.
• the paper with dispersion-based internal coating (for beverages) is comminuted using an Alpine cutting mill and water (5% solids) and then ground in a grinding roller mill with further addition of water so that a solids content of 2% is achieved.
• a grinding degree of 35-45 SR according to Schopper Riegler is aimed for.
• the coffee grounds are added, diluted with the appropriate amount of water to a solids content of 2%.
• the dispersion is slowly added to the fiber/coffee grounds slurry while stirring. When a good mixing is achieved, the Polymin SK is added. After a few minutes the liquor should be clear.
• the end point of precipitation can be seen when a sample of the fiber pulp poured onto a filter or sieve gives a clear filtrate.
• half of the cellulose fiber/coffee grounds/binder liquor is dewatered on a sheet former with a screen size of 20 ⁇ 20 cm.
• the dewatering is accelerated by applying a vacuum.
• the resulting fiber cake is further dewatered and compacted in a stacking press between rubber, filter paper, screen and a damp cloth. (Structure in the press: Rubber mat, filter paper, sieve, damp cloth, fiber CS cake, damp cloth, sieve, filter paper, rubber mat).
• the fiber coffee cake obtained in this way is then dried at RT or at temperatures of up to 100° C.
• the dried board obtained in this way can then be further compacted in a press after 24 hours of conditioning.
• the sheet produced in this way has a thickness of 0.63 mm and a density of 0.7 g/cm 3 .
• the tearing force, the elongation and the tear propagation force are determined on the plate.

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• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Dispersion Chemistry (AREA)
• Health & Medical Sciences (AREA)
• Polymers & Plastics (AREA)
• Organic Chemistry (AREA)
• Medicinal Chemistry (AREA)
• Materials Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Life Sciences & Earth Sciences (AREA)
• Wood Science & Technology (AREA)
• Mechanical Engineering (AREA)
• Paper (AREA)

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Citations (14)

• 2021
  • 2021-09-09 EP EP21195673.5A patent/EP4148174B1/de active Active
  • 2021-09-09 ES ES21195673T patent/ES3050637T3/es active Active
• 2022
  • 2022-09-09 US US17/941,258 patent/US12366018B2/en active Active

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